Professional Documents
Culture Documents
GAS TURBINES
Vivek Ghate GMS CPP vivek.ghate@ril.com
1 of 119
VMG/AG
30 June 09
Index
1. Basics of Gas Turbines. 2. Major Components of Gas Turbines.
30 June 09
GAS TURBINE
A gas turbine, also called a combustion turbine, is a rotary engine that extracts energy from a flow of combustion gas. It has an upstream compressor coupled to a downstream turbine, and a combustion chamber in-between.
3 of 119
VMG/AG
30 June 09
GAS TURBINE
By heating up compressed air, expanding it in nozzles mechanical/rotational energy is obtained.
Buckets
4 of 119
VMG/AG
30 June 09
Brayton Cycle
5 of 119
VMG/AG
30 June 09
(2-3) Isobaric Process - The compressed air then runs through a combustion
chamber, where fuel is burned, heating that aira constant-pressure process, since the chamber is open to flow in and out.
(3-4) Isentropic Expansion - The heated, pressurized air then gives up its
energy, expanding through a turbine (or series of turbines). Some of the work extracted by the turbine is used to drive the compressor.
6 of 119
VMG/AG
30 June 09
7 of 119
VMG/AG
30 June 09
Compressor & Turbine are coupled to common single shaft. Normally used in process where less speed variation is required. Due to larger rotor mass the speed can be easily kept constant. Extremely suitable for generator drives.
8 of 119 VMG/AG
30 June 09
In 2 shaft machines turbine is divided into High Pressure (HP) turbine & Low Pressure (LP) turbine. HP turbine & compressor are attached to one shaft & LP turbine is attached to another shaft. These machines provide wide speed range with sufficient power & efficiency. Well suited for mechanical drives & compressors.
9 of 119 VMG/AG
30 June 09
10 of 119
VMG/AG
30 June 09
11 of 119
VMG/AG
30 June 09
12 of 119
VMG/AG
30 June 09
13 of 119
VMG/AG
30 June 09
Turbine
Combustion chamber
Starting means
14 of 119
VMG/AG
30 June 09
TURBINE
3 Stage Impulse Turbine
COMBUSTION CHAMBER
10 combustors in annular space. 2 nos. Igniters in combustor no 1 & 10. 4 nos. Flame scanners in the combustor no 2,3 & 7,8.
15 of 119
VMG/AG
30 June 09
16 of 119
VMG/AG
30 June 09
17 of 119
VMG/AG
30 June 09
from 3 MW to 480 MW in a simple cycle configuration. Efficiency 30 to 39 %. Aircraft - Derivative Gas turbines: These are power generation units, which are prime mover of aircraft in the aerospace industry. Efficiency 35 to 45%. Industrial Type - Gas Turbines: In the range of 2.5-15 MW. Used extensively for compressor drive trains. Efficiency Less than 30%. Small Gas Turbines: In the range from about 0.5-2.5 MW. They often have centrifugal compressors & radial inflow turbines. Efficiency 15 to 25%. Micro - Turbines: In the range from 75 - 650 kW. Efficiency 15 to 20%.
18 of 119
VMG/AG
30 June 09
19 of 119
VMG/AG
30 June 09
Gas Turbine
MODEL Make Output (MW) Heat Turbine Exhaust Efficiency Pressure Flow Rate Speed Temp % Ratio (kg/sec) (kcal/kwh) (rpm) (C)
Saturn 20
Solar
1.2 3.897
4.35 5.925
3535 2960
2865 3001
24.3 29.1
30 28.7
6.8 10.3
13 8.4
22516 14200
16500 15400
6.55 15.4
17.7 27.3
504 560
527 496
Mars 100
LM1600PE SGT 500 UGT15000+
Solar
GE Siemens Zorya Mashproek t
10.69
14.898 17 20
2650
2544 2671 2389
32.5
33.8 32.2 36
17.4
21.3 12 19.4
11168
7900 3000 3000
42
49.8 92.5 72.2
488
479 375 412
VMG/AG
20 of 119
30 June 09
Gas Turbine
Gas Turbines up to 60 MW.
Various Manufacturers are:
Rolls Royce
21 of 119
VMG/AG
30 June 09
RB211 6761 DLE 2000 TRENT 60 DLE 1996 TRENT 60 WLE 2001
32 51 58
39.3 42 40
21.5 33 36
29.06 45 49.5
36 34 32.7
18 19.3 15.3
22 of 119
VMG/AG
30 June 09
46 45.48
2123.3 2123.5
40.5 40.5
30 30
130.45 130.91
3000 3000
445 450
MF221
1994
30
2689.69
32
15
108.18
7200
532.78
23 of 119
VMG/AG
30 June 09
24 of 119
VMG/AG
30 June 09
25 of 119
VMG/AG
30 June 09
Ansaldo Energia
ISO BASE HEAT TURBINE EXHAUST EFFICIENCY PRESS FLOW MODEL YEAR RATING RATE SPEED TEMP % RATIO (kg/sec) (MW) (kcal/kwh) (rpm) (Deg C) V64.3A V 94.2 V 94.3 A2 V 94.3 A4 1996 1981 1995 2004 68.5 166 272 279 2364.51 2500.63 2233.43 2200.66 34.7 34.4 38.5 39.1 15.8 11.8 17.4 17.7 191.4 510.0 657.3 668.2 3000 3000 3000 3000 588.89 546.11 575.00 577.22
30 June 09
SGT 1000F SGT 5 2000E SGT 6 3000E SGT 6 4000F SGT 5 3000E SGT 5 4000F
27 of 119
VMG/AG
30 June 09
28 of 119
VMG/AG
30 June 09
Type
CC SC
O/P (MW)
520 412.9
Freq (Hz)
50 50
Kcal/ kwh
1434.3 1481.2
CC
SC CC SC CC CC CC SC CC SC
390.8
255.6 193.2 126.1 117.7 75.9 64.3 42.1 67.2 45.4
50
50 50 50 50 50 50 50 50 50
1517.5
2331.7 1656.2 2546.0 1573.0 2460.3 1752.0 2682.6 1583.3 2348.1
MS9001E
MS6001FA
MS6001B
MS6001C
29 of 119
VMG/AG
30 June 09
GE H-System
First gas turbine ever to achieve the milestone of 60% fuel efficiency.
30 of 119 VMG/AG
30 June 09
S 109H
109H System Combined Cycle Power Plant
520 MW; Single shaft. Firing Temperature Class: 1430C (2600F) Heat Rate: 1435 kcal/kwh.
Efficiency: 60%
18 Stage Compressor; 23:1 Pressure Ratio; Airflow 687 kg/sec. NOx emissions: < 25 ppm. Steam Turbine: GE design; Reheat, Single flow exhaust. Generator: GE 550 MW LSTG; 660 MVA Liquid cooled. HRSG: 3 Pressure level reheat.
31 of 119
VMG/AG
30 June 09
Siemens
(SGT5-4000F)
278 MW 2200 kcal/kwh 39.10% 17.2 672.2 kg/sec 582 Deg C
Alstom
(GT26)
288 MW 2246 kcal/kwh 38.3% 32 633 kg/sec 615 Deg C
SIMPLE CYCLE
COMBINED CYCLE
Output Heat Rate Efficiency 390.8 MW 1517.5 kcal/kwh 56.70% 407 MW 1435 kcal/kwh 57.70% 410 MW 1488 kcal/kwh 57.8%
32 of 119
VMG/AG
30 June 09
H Class Comparison
GE
(S109H)
Siemens
(8000H)
Combined Cycle
Output
Heat Rate Efficiency Pressure Ratio Flow
520 MW
530 MW
33 of 119
VMG/AG
30 June 09
34 of 119
VMG/AG
30 June 09
102.998 98.44 50
41.01 40 31.5
LM6000PC
LM6000PD sprint LM6000PD LM2500RC LM2500RD LM2500PH GE 10 - 2
42.89
46.9 41.7 32.91 32.68 26.46 11.982
2060.25
2085.20 2110.92 2238.47 2243.76 2186.29 2557
29.2
30.9 29.3 28.5 23 23 15.5
3627
3627 3627 3600 3600 3000 11000
129
132 127 92 91 76 47
436
446 448 524 525 497 480
35 of 119
VMG/AG
30 June 09
36 of 119
VMG/AG
30 June 09
Size Influence Thermodynamic Influence Ambient condition Influence GT Speed Inlet & Exhaust Pressure Loss
37 of 119
VMG/AG
30 June 09
Compressor Fouling
Fouling rate is a function of
Environment Wind Direction Filtration System
38 of 119
VMG/AG
30 June 09
Size Influence
Greater Dimensions
Higher Output
39 of 119 VMG/AG
30 June 09
Thermodynamic Influence
Mainly determined by the design of the engine Main Component Efficiency Compressor Pressure Ratio Turbine Inlet Temperature
The combination of gas temperature and pressure ratio gives a specific output, exhaust temperature and thermal efficiency, which also are influenced by the components efficiency.
40 of 119
VMG/AG
30 June 09
The gas turbine nominal performance is related to: P = 1,013 bar T = 15C RH = 60%
41 of 119 VMG/AG
30 June 09
42 of 119
VMG/AG
30 June 09
43 of 119
VMG/AG
30 June 09
Humid air, which is less dense than dry air, affects output and heat rate, as shown in Graph.
44 of 119
VMG/AG
30 June 09
GT Speed
Ref: GE perf.curve GTF6SP
37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20
34.95 34.35 33.75 33.15 32.4 31.5 30.75 30 28.8 27.6 26.475 25.35 24.3 23.175 22.125 29.625 28.35 27.225 26.1 24.975 23.925 22.8 30.3 29.1 27.975 26.85 25.65 24.6 23.55 32.1 30.975 29.85 28.65 27.6 26.4 25.35 24.3 32.7 31.65
35.4
33.3 32.25 31.05 30.45 29.4 28.2 27.15 26.025 24.9 30 28.875 27.75 26.7 25.575
MW
95
96
97 5degC 35degC
98
99 15degC 40degC
100
101
103 30degC
104
105
speed %
20degC 45degC
45 of 119
VMG/AG
30 June 09
1.50% Power Output Loss 0.50 % Heat rate Increase 1.2 Deg F Exhaust temperature increase.
4 Inches H2O Exhaust Drop Produces:
0.50% Power Output Loss 0.50 % Heat rate Increase 1.2 Deg F Exhaust temperature increase.
46 of 119
VMG/AG
30 June 09
47 of 119
VMG/AG
30 June 09
GE GE GE SIEMENS GE GE GE
33.3 28.5 32.1 36 40.5 39.7 33.8 (sc) 52.0 (cc) 36.9 (sc)
Fr 9E
GE GE Fr 9 FA
GE
390.80
1517
56.7 (cc)
48 of 119
17
3000
641
602
VMG/AG
30 June 09
49 of 119
VMG/AG
30 June 09
Model
Fr 5 MS 6541 Fr 9E Fr 9FA
50 of 119
VMG/AG
30 June 09
T3 (C) 957
T4 WORK TURBINE COMPRESSOR WORK POWER (C) RATIO (MW) (MW) 487 0.361 0.380 0.421 0.457 0.358 0.355 73 99 300 559 127 82 46 61 174 304 82 53
%
63.86 61.96 57.93 54.29 64.20 64.47
362 1104 544 340 1104 543 407 1327 605 535 1260 450 416 1140 518
51 of 119
VMG/AG
30 June 09
40
80
30
70
20
60
10
50
40
Efficiency %
52 of 119
EFFICIENCY, %
VMG/AG
30 June 09
Efficiency, %
Efficiency %
53 of 119
30 June 09
Comparison
Model ISO Output Heat Rate Efficiency % Flow (lb/sec) Power consumed by Compressor % Firing Temp (Deg C)
MS-6541
37.5
2752
32.1
294.8
61.96
1104
Fr 9FA
255.6
2334
36.9
1412.4
54.29
1327
For every 100 Deg F/55.5 Deg C increase in firing temperature, the efficiency increases about 1.5%. So, 223 Deg C rise in firing temp increases the efficiency by 6%. Leading to improvement in heat rate by 165 kcal/kwh.
7 % reduction in compressor power consumption improves the heat rate by 211 kcal/kwh.
Remaining 2 % improvement in Heat rate as a result of:
GTD-222 Stage 2 Nozzle Stage 2 & 3 Honey Comb Shrouds 86i IGV setting Higher RPM Load Gear High Pressure Packing Brush Seal Improved Cooling Stage 1 Nozzle
54 of 119 VMG/AG
30 June 09
Approximately 20% of the Inlet Air to the Axial Flow Compressor gets lost to the Thermal cycle due to losses associated with cooling hot gas path parts or losses due to Large Clearances. Most uprates on Gas Turbines typically are achieved by Higher Airflow or Higher Firing Temperatures.
55 of 119
VMG/AG
30 June 09
56 of 119
VMG/AG
30 June 09
57 of 119
VMG/AG
30 June 09
58 of 119
VMG/AG
30 June 09
Type of fuel
Firing Temperature
Cyclic Effects
Steam or Water Injection Quality of Air
59 of 119
VMG/AG
30 June 09
60 of 119
VMG/AG
30 June 09
30 June 09
Results
1 hr of Liquid Fuel Operation
62 of 119
VMG/AG
30 June 09
63 of 119
VMG/AG
30 June 09
64 of 119
VMG/AG
30 June 09
Cyclic Effects
Each stop and start of a gas turbine subjects the hot gas path to significant thermal cycles. Control systems are designed and adjusted to minimize this effect. The severity is phenomenal in the case of emergency start and trips.
30 June 09
66 of 119
VMG/AG
30 June 09
67 of 119
VMG/AG
30 June 09
68 of 119
VMG/AG
30 June 09
69 of 119
VMG/AG
30 June 09
Advantage
139 C lower metal Temp. Lower Temp. gradient. Short length provide more stiffness and reduced cooling air.
70 of 119
VMG/AG
30 June 09
71 of 119
VMG/AG
30 June 09
72 of 119
VMG/AG
30 June 09
Turbine Components
There have been significant design and material improvements made to the turbine components to improve component designs which can withstand higher firing temperatures due to advanced materials and coatings, as well as the addition of air cooling for some of the components.
73 of 119
VMG/AG
30 June 09
BUCKETS
Stage 1 Bucket (FS2H)
Design
The original designs sharp leading edge has been blunted to allow more cooling air to flow to the leading edge, which reduces thermal gradients and cracks.
Materials
The original stage 1 bucket was IN- 738 is changed to an Equiaxed (E/A) GTD-111, a precipitation hardened, nickel-base super alloy, a greater low cycle fatigue. It also provides the industry standard in corrosion resistance.
Coatings
In 1997 the coating was changed again to GT-33 INCOAT. GT-33 is a vacuum plasma spray coating, an increased resistance to through cracking. INCOAT refers to an aluminide coating on the cooling holes passages.
74 of 119 VMG/AG
30 June 09
BUCKETS
Stage 2 Bucket (FS2F)
Cooling
The new stage 2 buckets contains internal air cooling ,allows for higher firing temperatures.
Tip Shroud
Shroud leading edge was scalloped & tip was thickened & shroud tapered. It resulted in 25% reduction in stress and 80% increase in creep life.
Materials
The original bucket was made of U-700, the material was changed to GTD-111, also a precipitation-hardened, nickelbase super alloy, to improve rupture strength. In addition it has higher low cycle fatigue strength
75 of 119 VMG/AG
Coating
GT 33 INCOAT
30 June 09
BUCKETS
Stage 3 Bucket (FS2K)
Design
The trailing edge was thickened, and the chord length increased, the shroud leading edge was scalloped, the shroud tip was thickened between the seal teeth, and the underside of the shroud was tapered. These design changes resulted in an increase in creep life of the bucket.
Materials
The stage 3 bucket was originally made of U-500, it was changed to IN-738, a precipitation hardened, nickel-based super alloy.
Process Change
A new process for the bucket which eliminates the need for the cold straightening step, thus eliminating the process induced strain in the material.
76 of 119
VMG/AG
30 June 09
NOZZLES
Stage 2 Nozzle (FS1P)
77 of 119
VMG/AG
30 June 09
SHROUD BLOCKS
Stage 1 Shroud Blocks (FS2C)
The stage 1 shroud block was redesigned for the 2055F/ 1124C firing temperature. The two piece design is film cooled using airflow from the stage 2 nozzle to inhibit cracking. The film cooling required additional flow which translates into a performance loss. The main advantage of the two piece design is that it allows the damaged caps to be replaced without Having to remove the shroud block bodies or turbine nozzles. The body and hook fit are made of310 stainless steel and the cap is made of FSX-414.
78 of 119
VMG/AG
30 June 09
SHROUD BLOCKS
Stage 2 & 3 Shroud Honey Comb Seal
i. ii. Honey Comb Shroud: Reduces Leakage Greater Rub Tolerance Requires Buckets with Cutter Teeth Provides a performance improvement up to 0.6% in both output and heat rate.
79 of 119
VMG/AG
30 June 09
MATERIALS
Turbine Blades
Turbine Nozzles
80 of 119
VMG/AG
30 June 09
MATERIALS
Combustors
Turbine Wheels
81 of 119
VMG/AG
30 June 09
MATERIALS
Compressor Blades
82 of 119
VMG/AG
30 June 09
83 of 119
VMG/AG
30 June 09
84 of 119
VMG/AG
30 June 09
Due to non-availability of spares, Mark IV system at RIL sites are under proposal for upgrade to Mark VI. Expected cost is Rs. 200 lacs per unit.
85 of 119
VMG/AG
30 June 09
Discrete Solid State Components ICs Relays & Solid State ICs & MPs ICs & microprocessor
Display
Input
Fault Tolerance
Enhancement
Integrated Circuits
Micro-Processor
86 of 119
VMG/AG
30 June 09
Control system
Communicates with the turbine to Measure, adjust the parameters
87 of 119
VMG/AG
30 June 09
Auxiliary
88 of 119
VMG/AG
IGV
CRANK MOTOR
AIR INLET CPD 8.55 barg Max. Vib 7.0 mm/sec
GEAR BOX
GENERATOR
WATTS VARS PF FREQ
NORMAL RUN STATUS SELECT2 PRESEL STATUS_FLD UNLOADING FSER_CONTROL SPEED-DROOP SPEED_LVL 14HS FLAME #A#B#C#D GT_SPEED 98.75 % TNR 102.57 % SPREAD_1 30 deg C FSR 64 % MSG_FLD1 SIMPLE CYCLE MSG_FLD2 IGV FULL OPEN SC43 AUTO SC43F NAPTHA LIQUID FUEL 100 % RT NAP/KER
Master Select
OFF CRANK FIRE AUTO CO-GEN SIMPLE 89 of 119
Master Control
START FAST START STOP DROOP
Load Control
BASE LOAD PRESEL MW SETPOINT
Fuel Select
GAS HSD NAP
100 75 50 25 0 LUBE OIL
VMG/AG
30 June 09
BOI
Mark-V Panel Backup operator Interface
90 of 119
VMG/AG
30 June 09
<S>
<R>
<C>
<T>
< P>
< PD >
< CD >
91 of 119
VMG/AG
30 June 09
92 of 119
VMG/AG
30 June 09
* Time is in Minutes
93 of 119
VMG/AG
30 June 09
94 of 119
VMG/AG
30 June 09
95 of 119
VMG/AG
30 June 09
96 of 119
VMG/AG
30 June 09
97 of 119
VMG/AG
30 June 09
98 of 119
VMG/AG
30 June 09
99 of 119
VMG/AG
30 June 09
100 of 119
VMG/AG
30 June 09
at different ambient.
The firing temperature remains constant even with increase in MW, FSR & CPR ratio with less exhaust temperatures.
101 of 119 VMG/AG
30 June 09
Acceleration Control
0.35 %/sec
102 of 119
VMG/AG
30 June 09
Manual Control
Manual Control Loop Can be used to limit fuel to prevent over firing and over riding active control.
103 of 119
VMG/AG
30 June 09
Shut down control loop reduces the fuel at a predetermined during shut down to reduce thermal stresses.
30 June 09
IGV Control
IGV Control Loop
Controls air fuel ratio Prevents Compressor Pulsations
105 of 119
VMG/AG
30 June 09
IGV Control
IGV scheduling is required to ensure the protection from Pulsation/Stall by excessive opening at lower speeds/loads and negative pressures at partial loads by less opening
IGV Schedule
Maintains higher Exhaust Temperature at partial loads for Combined Cycle Operation
106 of 119
VMG/AG
30 June 09
IGV Control
Isothermal
The exhaust temp. varies for simple and combined cycle operations. IGV temperature control never exceeds the base temperature control set point.
CPD
IGV control reference Maintains higher Exhaust Temperature at partial loads for Combined Cycle Operation
107 of 119
VMG/AG
30 June 09
Performance Benchmarking
108 of 119
VMG/AG
30 June 09
Purpose of Benchmarking
Gives feed back on relative performance.
Indicating opportunities for improvement. Un-earth and explore the outstanding Reliability issues. Highlight the areas for improvement. Target the initiatives for sustainable development.
109 of 119
VMG/AG
30 June 09
30 June 09
Benchmarking at a Glance Number of Emergency Trips Number of forced shutdowns These are numbers which indicate the number of equipment trips in each category. RIL benchmark for not more than 1 trip/year for one equipment.
111 of 119
VMG/AG
30 June 09
Benchmarking at a Glance
The Down time hours include planned and unplanned shutdown hours.
112 of 119
VMG/AG
30 June 09
Benchmarking at a Glance
GT open cycle heat rate
Total direct fuel fired in GT in Kcal Power generated from GT in kwh
113 of 119
VMG/AG
30 June 09
Benchmarking at a Glance
114 of 119
VMG/AG
30 June 09
Benchmarking at a Glance
115 of 119
VMG/AG
30 June 09
Benchmarking at a Glance
116 of 119
VMG/AG
30 June 09
117 of 119
VMG/AG
30 June 09
Sr. No. 1 2 3 4 5 6
118 of 119
VMG/AG
30 June 09
Thank You
119 of 119 VMG/AG